Diaper kit with miniaturized diaper by folding and vacuum-sealing

ABSTRACT

A diaper is folded about lengthwise foldlines between side elastic banded edges and is folded along a widthwise foldline such that the diaper length is reduced by at least 50%. A central portion of the diaper is visible and the remainder thereof is hidden from view within the folds. Thereafter, a height of the folded diaper is reduced by compressing the diaper with opposed surfaces of a press and the diaper is sealed within an encasement having an interior volume that closely corresponds to the diaper. Sealing is done under a vacuum sufficient to result in further compression of the diaper to a very firm and dense state in which the surface of the diaper is hard. The vacuum-sealed diaper is packaged with a diaper accessory with the diaper and accessory located within separate interior spaces isolated by an air impermeable material such that a pressure differential may exist therebetween.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority to, U.S.patent application Ser. No. 10/906,828, filed Mar. 8, 2005, pending,which is hereby incorporated herein by reference, and which applicationis a divisional application of and claims priority to U.S. patentapplication Ser. No. 10/665,169, filed Sep. 18, 2003, pending, which ishereby incorporated herein by reference, and which application is anonprovisional of, and claims priority to, U.S. Provisional PatentApplication No. 60/451,433, filed Mar. 4, 2003, expired, which is herebyincorporated herein by reference.

BACKGROUND

The present invention relates generally to disposable packaged diapersand related infant and incontinent adult care accessories. Moreparticularly, the present invention relates to a reduced size packageddiaper, and related infant and incontinent adult care accessories andkits.

Diapers are generally a necessity for very young children andincontinent adults. Individuals incapable of controlling the release ofbodily waste in a manner sufficiently reliable to enable the use ofrestroom facilities, and those caring for such individuals, typicallyneed to carry extra disposable diapers and changing accessories. This istypically because it is difficult to predict when a diaper worn by anindividual may need to be changed. Caretakers of babies and othersrequiring diapers often carry spare, clean diapers for this reason.

Many of the following discussions and examples are directed to use ofdiapers in infant care. However, it will be apparent that many of thesame considerations apply to use of diapers for non-infant, incontinentpersons.

Storage and carriage of clean diapers is often inconvenient. Forinstance, disposable diapers are generally rather bulky items not givento easy storage or carriage in a purse, pocket, or otherwise about theperson. In addition, the problem can be acerbated in that diapers can besubject to expansion from the typically somewhat compressed state inwhich they are normally provided to consumers, especially incircumstances where the diapers are subject to contact with other itemswithin a storage bag. For example, many disposable diapers are providedin a bi-fold configuration meant to minimize the space taken in storingthe diaper. However, after being removed from their original packaging,bi-fold diapers often unfold or otherwise expand to consume an evenlarger storage space. Thus, disposable diapers can become more bulky anddifficult to carry than when in their nominal, packaged condition.

In addition, it is often the case that it is not sufficient to simplychange a soiled diaper and replace it with a clean diaper. For instance,cleaning of the individual who wore the diaper may need to be performedwith diaper accessories, such as moist wipes. Also, it may be necessaryto apply ointment or powder to the individual wearing the diaper totreat or prevent incidents of diaper rash or other skin conditions. Dueto these considerations, caretakers of individuals requiring diapersoften carry clean diapers and diaper changing accessories in a dedicatedcontainer, is often referred to as a “diaper bag.” By doing so, when itbecomes necessary to change a diaper, all of the materials needed by thecaretaker are available in one location.

While a conventional diaper bag provides a dedicated container in whichdiapers and diaper accessories can be stored and carried, therequirement of carriage of a diaper bag often adds to the difficulty ofa caretaker's responsibility. For example, parents of young childrenoften must carry a purse or briefcase for the parent's own needs. Inaddition to this, the parent may need to carry the young child; and, ofcourse, the child's diaper bag. This can leave the parent with no freehands for other tasks.

While conventional clean diapers and diaper changing accessories can bestored and carried in other carrying containers such as purses,backpacks, briefcases, etc., the bulky nature of conventional disposablediapers results in the diapers occupying a relatively large space withinthe carrying container. In addition, diaper changing accessories such asmoist wipes, ointment, powder, etc., add to the space consumed byconventional clean diapers and can be difficult to locate among otheritems stored in the backpack, purse, case, or the like.

Where the diapers being carried by the caretaker are for bottle feedinginfants, the problems discussed above are further exacerbated by theneed to carry materials for feeding the baby. In addition to theaccouterment necessary to attending to changing the baby's diaper,things such as bottles, nipples, containers of formula or milk, etc.,generally must also be carried.

SUMMARY OF THE INVENTION

It has been recognized that it would be advantageous to develop apackaged diaper that requires a relatively small amount of storagespace. In addition, it has been recognized that it would be advantageousto develop a diaper and related accessory kit that consumes a relativelysmall amount of space while providing substantially all of the materialsnecessary to change an individual's diaper. It has also been recognizedthat it would be advantageous to develop an infant care kit thatconsumes a relatively small amount of space while providingsubstantially all of the materials necessary to feed the infant andchange the infant's diaper.

The invention provides a packaged diaper, including a diaper, having afirst, nominal size, and a second, reduced size, the reduced size of thediaper being convenient for carriage and storage of the diaper. Anencasement can also be provided, in which the diaper can be disposed inthe second, reduced size. The encasement can confine the diaper so thatthe diaper is retained in its reduced size by the encasement and so thatthe diaper is returned to its nominal size upon opening of theencasement.

In accordance with another aspect of the invention, a packaged diaper isprovided, including a diaper, having a first, nominal configurationcharacterized by a nominal length, width and height, and a second,reduced configuration characterized by a second, reduced length, widthand height. The reduced length can be between about 2 inches to about 4inches, the reduced width can be between about 1.0 inch to about 2.5inches, and the reduced thickness can be between about 0.5 inches toabout 1.5 inches. An encasement can also be provided, in which thediaper can be disposed and retained in the second, reducedconfiguration.

In accordance with another aspect of the invention, a packaged diaper isprovided, including a diaper, having a first, nominal size and shape,and a reduced, substantially cylindrical size and shape. The reduced,substantially cylindrical shape can have a diameter between about 0.5inches to about 1.5 inches and a length between about 2 inches to about4 inches. An encasement can also be provided, in which the diaper can bedisposed and retained in the reduced, substantially cylindrical shape.

In accordance with another aspect of the invention, a packaged diaper isprovided, including a diaper having a first, nominal volumetricconfiguration characterized by a nominal length and width of the diaper,and a second, reduced volumetric configuration characterized by areduced length and width of the diaper. An encasement can also beprovided, the encasement formed of a substantially air impermeablematerial. The diaper can be disposed in the encasement in the second,reduced volumetric configuration and the encasement can be at leastpartially evacuated of air so as to contain the diaper in at least apartial vacuum state. Differential pressure within and without theencasement can maintain the second, reduced volumetric configuration ofthe diaper and the encasement can be sealed to confine the diaper sothat the diaper is returned to its nominal volumetric configuration uponopening of the encasement.

In accordance with another aspect of the invention, a method ofpackaging a diaper is provided and includes the steps of: a) folding thediaper at least once along both a lengthwise and a crosswise aspect ofthe diaper; b) disposing the folded diaper within an encasementcomprised of a substantially air impermeable material; c) evacuating airfrom the encasement and the folded diaper; and d) sealing the encasementto maintain a vacuum created within the encasement and the foldeddiaper.

In accordance with another aspect of the invention, a method ofpackaging a diaper is provided and includes the steps of: a)volumetrically reducing a size of the diaper to a size convenient forcarriage and storage of the diaper; b) disposing the volumetricallyreduced diaper within an encasement; and c) maintaining thevolumetrically reduced size of the diaper with the encasement.

In a more detailed aspect, the encasement can facilitate this by virtueof its hoop strength and/or by means of a pressure differential actingupon the encasement.

In accordance with another aspect of the invention, a diaper changingkit is provided and includes a packaged diaper in accordance with one ormore previously set forth aspects of the invention, at least one diaperaccessory, and a container in which the packaged diaper and the diaperaccessory can be disposed. In a more detailed aspect, the accessory canbe one or more of: a) a moistened wipe; b) baby powder; c) a medicament;d) a swab; e) a lotion; and, a disposal bag for a dirty diaper. Inanother more detailed aspect the container can be configured to have afirst, oversized size and shape and a second smaller size and shape, andto also function as a disposal container for a dirty diaper.

In accordance with another aspect of the invention, an infant care kitis provided and includes a diaper, a diaper accessory, a portion ofinfant food and an infant feeding assembly. The infant feeding assemblycan have a hollow body and a nipple portion couplable thereto. Thediaper, diaper accessory, and portion of infant food can each bedisposed in the infant feeding assembly. The infant feeding assembly canbe configured to: i) contain each of the diaper, at least one diaperaccessory and at least one portion of infant food; and ii) upon removalof the diaper and diaper accessory, receive the portion of infant foodwithin the hollow body and deliver the infant food to an infant with thefood delivery device. In a more detailed aspect a warming pack can alsobe provided for warming the infant food.

In accordance with another aspect of the invention, a packaged diaper isprovided and includes a diaper, having a first, nominal size, and asecond, reduced size, the reduced size of the diaper being convenientfor carriage and storage of the diaper. A restraint can also beprovided, in which the diaper can be disposed in the second, reducedsize. The restraint can confine the diaper so that the diaper isretained in its reduced size by the restraint and so that the diaper isreturned to its nominal size upon opening of the restraint.

In accordance with another aspect of the invention, a packaged diaper isprovided and includes a densified diaper volumetrically reduced to asecond reduced volume and increased density from a first greater volumeand lesser nominal density. The reduction of the diaper can entailreduction in one or more dimensions. An encasement can also be providedin which the diaper can be disposed in the second reduced volume. Theencasement can confine the diaper so that the diaper is retained in thereduced volume by the encasement.

In accordance with another aspect of the invention, an expandable diaperis provided and includes a diaper being reduced to a second, reducedsize from a first, nominal size, the reduced size of the diaper beingreduced in at least two dimensional directions relative to the nominalsize. An encasement can also be provided in which the diaper can bedisposed in the second, reduced size. The encasement can confine thediaper so that the diaper is retained in the reduced size by virtue ofthe encasement.

In accordance with another aspect of the invention, a packaged diaper isprovided and includes a diaper, having a first, nominal size, and asecond, reduced size, the reduced size of the diaper being convenientfor carriage and storage of the diaper. A restraint can also be providedin which the diaper can be disposed in the second, reduced size. Therestraint can confine the diaper so that the diaper is retained in itsreduced size by the restraint and so that the diaper is returned to itsnominal size upon opening of the restraint.

Additional features and advantages of the invention will be apparentfrom the detailed description which follows, taken in conjunction withthe accompanying drawings, which together illustrate, by way of example,features of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a top view of a diaper in a nominal configuration inaccordance with an embodiment of the present invention;

FIG. 1B is a side view of the diaper of FIG. 1A;

FIG. 2A is a top view of a diaper in a volumetrically reducedconfiguration in accordance with an embodiment of the present invention;

FIG. 2B is a side view of the diaper of FIG. 2A;

FIG. 3A is a perspective view of a diaper in accordance with anembodiment of the invention;

FIG. 3B is a perspective view of the diaper of FIG. 3A in the process offolding the diaper along a lengthwise aspect of the diaper;

FIG. 3C is a perspective view of the diaper of FIG. 3B in the process offolding the diaper along a crosswise aspect of the diaper;

FIG. 3D is a perspective view of the diaper of FIG. 3C being disposedwithin an encasement;

FIG. 3E is a perspective view of the diaper of FIG. 3D held under vacuumwithin the encasement of FIG. 3D;

FIG. 4 is an end view of a packaged diaper having a reduced volume in asubstantially cylindrical shape in accordance with one aspect of theinvention;

FIG. 5 is a perspective view of a diaper kit in accordance with oneaspect of the invention;

FIG. 6 is a perspective view of another diaper kit in accordance withone aspect of the invention;

FIG. 6A is a perspective view of a diaper wipe configuration usable withthe kit of FIG. 6 in one example in accordance with one aspect of theinvention;

FIG. 7 is a perspective view of an infant care kit in accordance withone aspect of the invention;

FIG. 8 is a perspective view of a master container in accordance withone aspect of the invention;

FIG. 9A is a top view of another diaper kit in accordance with oneaspect of the invention;

FIG. 9B is a side view of the diaper kit of FIG. 9A;

FIG. 9C is a side view of another example diaper kit in accordance withone aspect of the invention;

FIG. 10A is schematic view of a step of a process of packaging a diaperin accordance with one aspect of the invention;

FIG. 10B is schematic view of another step of the process of FIG. 10A;

FIG. 10C is schematic view of another step of the process of FIG. 10A;

FIG. 10D is schematic view of another step of the process of FIG. 10A;

FIG. 10E is schematic view of another step of the process of FIG. 10A;

FIG. 11A is a perspective view of a diaper held by a restraint inaccordance with one aspect of the invention;

FIG. 11B is a perspective view of a diaper held by another restraint inaccordance with one aspect of the invention;

FIG. 12 illustrates a photograph of both an unpackaged diaper havinggraphical indicia printed thereon and a corresponding diaper that hasbeen vacuum-sealed in accordance with the invention;

FIGS. 13–15 illustrate photographs showing the folding of an unpackageddiaper in preparation for vacuum-sealing of the diaper;

FIGS. 16–18 illustrate photographs showing compression of the diaperusing a clamping device in preparation for vacuum-sealing of the diaper;

FIGS. 19–21 illustrate photographs showing insertion of a compresseddiaper into a transparent encasement;

FIGS. 22–25 illustrate photographs showing steps the vacuum-sealing ofthe compressed diaper within the encasement using a “SUPER VAC”vacuum-sealing machine; and

FIG. 26 illustrates a photograph showing the resulting vacuum-sealeddiaper within the encasement.

DETAILED DESCRIPTION

Reference will now be made to the exemplary embodiments illustrated inthe drawings, and specific language will be used herein to describe thesame. It will nevertheless be understood that no limitation of the scopeof the invention is thereby intended. Alterations and furthermodifications of the inventive features illustrated herein, andadditional applications of the principles of the inventions asillustrated herein, which would occur to one skilled in the relevant artand having possession of this disclosure, are to be considered withinthe scope of the invention.

As illustrated in FIGS. 1A through 2B, an exemplary packaged,disposable, diaper 10 is sized and shaped to consume a considerablysmaller volume and be more conveniently shaped than conventionaldisposable diapers. As illustrated, the packaged diaper 10 begins as adiaper 12 nominally sized and shaped in accordance with conventionaldiapers. The diaper can be one of a variety of types known to those inthe art, and can be formed of a variety of materials. The diaper can bedisposable or non-disposable (i.e., resusable).

As shown in FIG. 1A, the diaper begins with a first, nominal volumetricconfiguration characterized by a nominal length L and nominal width W ofthe diaper. As used herein, the term “nominal” is understood to mean tobe the normal, post manufacturing state in which it is ready to beunfolded and worn, in reference to the various dimensions of the diaper.Thus, the diaper 12 can have a first size having a height, width andlength of nominal size, such as conventionally provided to consumers.While not so required, the diaper 12 can include upper 12 a and lower 12b portions, which can correspond to a front and back of the diaper. Manyconventional diapers are provided with a front and back portion ofdifferent configuration.

As shown in FIGS. 2A and 2B, an example of a packaged diaper 10, afterbeing prepared in accordance with the description to follow below,includes a diaper 12 having a second, reduced volumetric configurationcharacterized by a reduced length L₂ and width W₂ of the diaper 12. Thereduced volumetric configuration can differ from the nominal volumetricconfiguration in width, height, thickness, volume and overall size. Aswill be appreciated from the figures, not only is the volume of thepackaged diaper reduced overall, but in the example embodiment at leasttwo of the: 1) length; 2) width; and, 3) height, can also be reduced.Thus, the diaper can be reduced in volumetric configuration to consumemuch less space than the diaper consumes when in the nominalconfiguration.

As mentioned, the diaper 12 can be disposed in an encasement 14, whichcan be formed of a substantially air impermeable material. By disposingthe diaper in the encasement in the second, reduced volumetricconfiguration, a packaged diaper is provided that consumes much lessspace than the when in its nominal configuration. By “substantially airimpermeable,” what is meant is that the permeability is low enough thatthe product has a reasonable shelf life without significant expansion.

As an example, it has been found that by drawing a vacuum down to about5 mbar at room temperature and pressure at a location about 5,000 feetelevation above mean sea level, the volume of the diaper can be reducedto as little as ⅓ or ¼ that of the nominal volume. Similar results areto be expected at locations of different elevation. However, as isknown, at lower elevations a greater vacuum can be drawn to allow forsubsequent transportation of the packaged product to higher elevations.For example, vacuum packaging using a vacuum down to 1 or 2 mbar iscommon at lower elevations. Thus, in the space required to store oneconventional diaper, three, four, or more, diapers packaged inaccordance with the invention can be stored. The reduced volume packageddiapers are not only advantageous in reducing storage space, the spacerequired for packaging, shipping, etc., is also reduced, leading toconsiderable cost savings in associated processes.

While the reduced volume configuration can be created and maintained ina number of ways, in the embodiment shown in FIGS. 2A and 2B, thepackaged diaper 10 includes encasement 14, which can encompass thereduced volume diaper. Once the diaper 12 is disposed within theencasement, the encasement can be at least partially evacuated of air soas to contain the diaper in at least a partial vacuum state. Theevacuation of air from within the diaper and encasement can be done in anumber of ways, such as by conventional vacuum-packing methods.

For example, according to at least one conventional vacuum-packingmethod known to those skilled in the relevant art, an article to bevacuum-packed is inserted into an unsealed encasement formed of asubstantially air-impermeable flexible material. The unsealed encasementwith the article therein is then placed onto the deck of a vacuumsealing machine. The lid of the machine is then lowered establishing aseal with the deck to define a chamber between the deck and the lid withthe unsealed encased article within the chamber. The machine thenevacuates ambient air from the chamber creating at least a partialvacuum state within the chamber and within the interior space of theunsealed encasement with the article therein. The machine then seals theencasement to maintain at least a partial vacuum state therein. Ambientair pressure is then restored to the chamber effecting a pressuredifferential across the sealed encasement. Insofar as the article withinthe sealed flexible encasement is compressible, the pressuredifferential acts upon the encasement to compress the article andmaintains the article in a reduced volume that is less than the volumeof the article at the time the encasement was sealed (before ambient airpressure was restored to the chamber).

Upon evacuation of air from the encasement, the encasement can besealed, for example at an edge portion 16 to maintain the vacuum withinthe encasement and diaper 12. In this manner a differential pressure canbe created within and without the encasement to maintain the second,reduced volumetric configuration of the diaper. While the encasement isshown in FIG. 2B as sealed at an edge portion 16, it will be understoodthat the encasement can be sealed conventionally in a variety of ways ina variety of locations.

As the encasement 14 configured to confine the diaper 12 is unsealed,the diaper is able to return to its nominal volumetric configuration.That is, user can cut, tear, remove a portion of the encasement, orotherwise break the airtight seal of the encasement; after which, thediaper 12 will no longer be subject to confining force due to theencasement and/or a pressure differential. Unopposed rebound forces inthe materials from which the diaper is made will tend to return it toits nominal configuration. The encasement can include a means tofacilitate opening, such as a notch or another intentionally formeddiscontinuity (not shown) provided in the encasement to aid in openingthe encasement. In one embodiment a tear-away band, or the like,provided with a grasping tab (not shown) can be provided to facilitateopening by rupturing the encasement as it is pulled away therefrom. Oneof many other well known ways to provide a more easily broken-openencasement can be used to facilitate opening the packaging.

As described in further detail below, the reduced volumetricconfiguration can be achieved in a number of ways, and in the embodimentshown in FIGS. 2A and 2B, the volumetrically reduced configuration iscreated by foldingly reducing a length and width of the diaper 12;increasing its thickness. The folded diaper is then vacuum-packed toreduce its thickness (as well as its width and length to a lesserextent). As used herein, the term “foldedly reduced” is meant toindicate the case wherein a diaper is folded or rolled over or underitself to thereby reduce a dimension of the diaper.

While the final size of the reduced volume diaper can vary, in oneaspect of the invention, the reduced length and width can each be lessthan about ½ of the nominal length and width, respectively, of thediaper. In another aspect of the invention, the foldedly reduced lengthof the diaper can be less than about ⅓ and/or ¼ of the nominal length ofthe diaper. In this manner, as shown by comparing FIGS. 1A and 1B withFIGS. 2A and 2B, the overall width and length of the diaper can besubstantially reduced. While a height dimension, corresponding tothickness, may be increased, it is not increased to exceed the width orthe length of the diaper. This results in a more convenient and compactsize overall.

The inventor has found that a conventional size 6 diaper can be reducedin size and volume from a nominal size of approximately 9″ long by 4.5″wide by 0.25″ to 1″ in height/thickness (depending on expansion afterremoval from conventional packaging) to a reduced size of approximately3.5″ long by 2.25″ wide by 1″ in height. In the embodiment shown inFIGS. 2A and 2B, the packaged diaper 10 can include a reduced volumetricshape configuration which comprises a substantially rectangular shape,although other shapes are contemplated as well, as discussed in furtherdetail below. In this manner, the packaged diaper can be easily carried,handled and stored within a purse, pocket, bag or other place orcontainment for carriage.

The packaged diaper in a densified state can thus be made pocket sized,or pocketable. As used herein that means that it is conveniently sizedfor carriage, for example about the size of a conventional cigarettepackage or smaller. One way to characterize this is that two of thethree dimensions of height width and length, when added together, areless than 10 cm, and the greatest of the three does not exceed 10centimeters. That said, all pocket sized items may not strictly fit thisdefinition, but it is a definite guide in understanding what is meant bythe term as used herein.

It will be appreciated that in this example the present inventionprovides a compact, efficiently sized packaged diaper that requiressubstantially less space than conventionally packaged diapers. Thepresent invention can be advantageously utilized by a variety ofpersons, including incontinent minors and adults, and caretakers ofindividuals requiring diapers.

For example, parents of young children will benefit from the inventionin that one or more diapers 10 can be easily stored in a pocket, orwithin a purse, briefcase, backpack or other storage bag and consumerelatively little space. Similar benefits can be obtained with regard toincontinent adults, as adult diapers are generally even more bulky anddifficult to store and carry than are smaller, children's diapers. Also,incontinent adults who may be otherwise embarrassed by having to carryspare clean diapers will likely find the packaged diapers in accordancewith the invention to be much more discreetly transportable, andtherefore the carriage of such spare diapers much less noticeable byothers.

In addition, in one aspect of the invention a packaged, pocketablediaper is provided and can include an encasement configured to encaseand confine a diaper disposed therein. A diaper can be disposed withinthe encasement to be confined by the encasement in a size that isvolumetrically reduced relative to a nominal size of the diaper. Thevolumetrically reduced size of the diaper is characterized in that thediaper is pocketable upon a person of an individual. As used herein, theterm “pocketable” is to be understood to indicate a configuration of thediaper in which the diaper can be easily placed within and removed froma pocket of an item of clothing or accessories worn or carried byindividuals. For example, the pocketable diaper can be held within ashirt, jacket or pants pocket or stored or carried in a handbag, purseor briefcase, etc., and can be substantially undetectable by otherindividuals. In this manner, an incontinent adult can carry thepocketable diaper without worrying that others will be aware that thediaper is being carried. Also, an adult caretaker of an infant can carrya diaper for the infant in a manner that does not detract from aphysical appearance of the adult and does not require additionalbaggage.

In several embodiments of the invention, a reduced diaper is provided.The reduced diaper is densified by volumetric reduction from a firstgreater volume and lesser nominal density to a second reduced volume andincreased density. An encasement can also be included and the diaper canbe disposed in the encasement in the second reduced volume. Theencasement can thereby confine the reduced diaper so that the diaper isretained in the reduced volume by the encasement. The volumetricreduction can entail dimensional reductions in width, thickness, length,and diameter. In this manner, a volumetrically reduced, space-efficientdensified diaper is provided that can be easily stored and carried by anindividual in a discreet manner. Upon release of the reduced diaper fromthe encasement, the diaper can be volumetrically expanded and used inthe same manner as conventionally packaged diapers.

As used herein, the term “encasement” is to be understood to encompass abroad range of materials and configurations for containing orrestraining or enclosing a volumetrically reduced diaper. For example,the encasement may completely encompass a diaper and hold the diaperunder a vacuum seal or other pressure differential. In addition, theencasement may only partially encompass the diaper to maintain thecompressed state of the diaper. Moreover, it is intended to beunderstood herein to be synonymous with restraint (as discussed below)or enclosure, or containment, in this context. The salient point beingthat it constrains, by some means, the densified diaper from expanding.Other encasements besides the examples shown can also be utilized, aswould occur to one skilled in the art.

Shown in series in FIGS. 3A through 3E is one aspect of the invention inwhich a diaper is reduced from its nominal volume or size to a reducedvolume or size. Diaper 12 begins with a nominal volumetricconfiguration, sized and shaped as may be conventionally provided by amanufacturer of the diaper. In this embodiment, the diaper is reduced involume by fold 17 along a lengthwise aspect of the diaper, shown at line18. In FIG. 3C, the diaper 12 is folded at 19 along a crosswise aspectof the diaper, shown at line 20. Progressing to FIG. 3D, once the diaperhas been folded a desired number of times; the folded diaper is disposedwithin encasement 14, which is formed of a substantially air impermeablematerial. Encasement 14 can then be evacuated to form a relative vacuumwithin the encasement, after which the encasement can be sealed tomaintain the vacuum in the diaper and the encasement.

It will be understood by those skilled in the art that the process offorming a vacuum within the diaper and the encasement will extract atleast a portion of air contained within the diaper. By removing amajority of excess air from the diaper, the diaper can be compressedupon itself by atmospheric pressure and consume a reduced amount ofspace corresponding to the amount and volume of air removed from thediaper.

In addition to the process illustrated in FIGS. 3A through 3E, inanother aspect of the invention, a method of packaging a diaper isprovided and includes the steps of volumetrically reducing a size of thediaper to a size convenient for carriage and storage of the diaper. Thevolumetrically reduced diaper can then be disposed within an encasement.The volumetrically reduced, convenient size of the diaper can bemaintained by a pressure differential acting upon the encasement. Asused herein, the term “convenient size” is understood to refer to a sizeand configuration of a diaper that can be easily and conveniently storedin a pocket, handbag, purse, etc., and consume very little space withinthe pocket, handbag, etc. Such a size will be appreciated to beessentially a “pelletized” or “capsulated” or “pocket sized” or“pocketable” (as defined above) version of the diaper, having bulk dueto air spaces removed, and will be generally cylindrical, rectangular,etc, and can have rounded or square corners. Generally, the largestdimension will be about four inches or less. However, for certainspecialized applications such as kits contained in a feeding bottle, alonger, more “sticklike” shape may be used in one embodiment. Butlikewise a cylindrical or square configuration having height, width, andlength dimensions of roughly equal magnitude can also be advantageous insuch a kit in another embodiment. The salient point is that the size isconvenient to carry and conceal.

The size of the diaper can be volumetrically reduced in a number ofmanners, including pressing the diaper into a mold or other cavity. Inthis example, the encasement in which the diaper is disposed can besized and shaped to correspond closely to the volumetrically reducedsize of the diaper. Once disposed within the encasement, the forceapplied to compress the diaper into the mold can be released, afterwhich the diaper will tend to return to its nominal size and shape, butwill be restrained by the encasement. The pressure differential actingupon the easement will thus be the result of the diaper tending toexpand into its nominal configuration. An equilibrium will be reachedbetween a) the restoring force tending to expand the diaper; and b) acombination of the hoop strength (resistance to expansion of theencasement via deformation of the encasement) and the pressuredifferential tending to compress the diaper. Depending on the materialfrom which the encasement is made, this can be made to be predominantlyhoop strength or predominantly air pressure differential.

While the example packaged diaper shown in many of the figures of thisdisclosure includes a generally rectangular shape, it is contemplatedthat the volumetrically reduced diaper can be of a variety of sizes andshapes. For instance, as shown in FIG. 4, volumetrically reduced diaper12 a can have a substantially cylindrical shape. This embodiment may bebeneficial, for example, in applications in which the diaper is to bestored in rounded or cylindrical receptacles, such as cans or tubes. Aswill be appreciated, by forming encasement 14 a from a flexible,substantially air impermeable material, a vacuum formed within theencasement will force the encasement to conform to the general shape ofthe reduced volume diaper. In this manner, the diaper can be formed in avariety of reduced volume shapes for a variety of applications.

In another example embodiment the encasement shape can control the shapeof the packaged diaper. For example, a diaper can be compressed into anencasement within a mold cavity which encasement has a shape whichessentially follows the shape of the mold. Thereafter the encasementmaintains that shape, though the diaper may expand slightly against thehoop strength, air pressure differential, or combination thereof.

As illustrated in FIG. 5, in another aspect of the present invention adiaper kit 40 is provided. The kit can include a packaged diaper 10 inaccordance with the embodiments discussed above and at least one diaperaccessory 42. A container 44 is also provided, in which each of thepackaged diaper and the diaper accessory are disposed. The diaperaccessory can be a variety of items, including, but not limited to, adiaper rash ointment or other medicament, talcum powder/baby powder, alotion, moist or dry wipes, cotton swabs, dirty diaper disposal bag,etc., as may be needed in caring for an infant or incontinent person, aswill be known to one skilled in the art of providing products for careof such persons. In the example embodiment shown, a packet of ointment42A is included in the kit, as are moist wipes 42B.

Thus, in one example, substantially all of the materials necessary forchanging a soiled diaper are provided in a small, space optimized kitthat can be easily carried or stored by a caretaker of an individualrequiring diapers. The kit can be advantageously used as a daily stapleof caretakers, or may be used in specialized circumstances such asoutdoor activities, travel, or business or recreational events away fromhome, or other situations in which space and convenience of carriage maybe of a premium. In such circumstances the caretaker may wish tominimize the number of articles needing carriage, and can advantageouslycarry one or two kits, as may be needed, and dispense with theconventional diaper bag that would otherwise have to be carried duringthe event or activity. Also, the reduced size of the present diaper kitcan allow one or more kits to be stored in an out-of-the-way location,such as a glove box of a car, and retrieved in “emergency” situations inwhich spare diapers were forgotten or consumed.

In another embodiment, the kit can be configured for use by anincontinent adolescent or adult. The kit can further include supplies totouchup stains on clothing. It can contain a small container of perfumeor cologne, a small container of odor reducing spray, or other itemswhich an incontinent adult may find needful and reassuring to carry, inaddition to supplies which customarily may be needed to change a diaper,including a clean diaper, wipes, and lotion, ointment or othermedicament, to name some examples.

As shown in FIG. 5, the diaper kit 40 can include a container 44 that issubstantially rectangular in shape. Such kits can be easily stacked andstored and will fit neatly into a pocket, purse or other baggage. Inanother embodiment, as shown in FIG. 6, the container 46 can besubstantially cylindrical in shape. In this embodiment, the diaper 12 bcan be formed in a cylindrical shape, or other shape to facilitatemaximum use of available space within the cylindrical container. Alsoincluded in the illustrated example shown in FIG. 6 are moist wipes 42Cwhich can be arranged in a disk-like or toroidal configuration fordisposal within the cylindrical container. With reference to FIG. 6A,the individual wipes 43 are accordion folded, then rolled about an axis45 transverse to the folds. A surprisingly large number of wipes thusconfigured can be fit into a surprisingly small space. In this manner, 6or 7 wipes or another selected number of wipes can be stored within thecontainer 46 to ensure ample supply.

In another aspect of the invention, illustrated by example in FIG. 7, aninfant care kit 49 can be provided which includes a diaper 50, one ormore diaper accessories 52 and a portion of infant food 54. An infantfeeding bottle assembly is also provided having a hollow body 56 and anipple food delivery portion 58 of the device couplable thereto. A cover59 a or 59 b can be provided, which keeps the feeder portion sanitary.This can be a throwaway tear-off film cover (e.g. 59 b) or a moreconventional replaceable cap (e.g. 59 a). The feeding apparatus can besingle use (i.e., disposable) or reusable. As shown, the diaper, diaperaccessory, and portion of infant food can be disposed within the infantfeeding assembly for convenient carriage. The infant feeding assemblycan thus be configured to: i) contain each of the diaper, diaperaccessory and portion of infant food; and ii) upon removal of the diaperand diaper accessory, receive the portion of infant food (and water, ifapplicable) within the hollow body and thereby enable delivery of theinfant food to an infant via a food delivery device erstwhile acting asa container for the kit. In one embodiment the nipple portion can beconfigured for delivery of baby formula, and in another embodiment itcan be configured for delivery of a flowable baby food such as aformula/cereal mixture, creamed vegetables or fruit, or the like. In oneembodiment the baby food can be in powder form, reconstituted byaddition of water. A chemical warming pack (similar to or the same as aconventional hand warming pack) can be provided for use in warming thebaby formula or other baby food.

In this example implementation, substantially all of the materialsnecessary to feed and change a diaper of an infant are provided in acompact, easily carried kit. A caretaker of the infant can use the kitto store the provided items, and when desiring to feed the infant, canprepare the portion of infant food and feed the infant with the infantfeeding assembly, shown in this embodiment as similar to a conventionalbaby bottle, but provided with a detachable bottom.

As shown in the illustrated example, the hollow body 56 of the feedingassembly 49 can be substantially cylindrical in shape, although othershapes are also contemplated, such as squared, triangular, and otherpolyhedral cross-sectional shapes. The portion of infant food caninclude a variety of foods suitable for consumption by infants,including powdered baby formula and condensed baby formula, freezedried, powdered, concentrated creamed vegetables and fruits and otherbaby foods, as well as cereal mixes, etc. A caretaker can easily removeall items from the feeding assembly, configure it for feeding, andreturning the portion of infant food (with water, as mentioned, ifnecessary, or other fluid which can be added to the infant food) and thefood can be fed to the infant via a food delivery device 58, aconventional baby bottle nipple in the illustrated embodiment.

In one embodiment, the feeding apparatus can include a double wallconfiguration to provide increased insulation so as to keep formula orother baby food at a desired temperature for a longer period of time. Tofacilitate this, or, to provide initial warming when hot potable wateris unavailable, a heat source 55, as mentioned, can also be disposedwithin the feeding assembly. The heat source can be configured toprovide heat for warming the portion of infant food, as well as anyfluid having been added to the infant food. In situations where it maybe necessary to add cold fluid such as milk or water to the infant food,the fluid and food can be warmed to a temperature well tolerated andmore acceptable to an infant. As mentioned, the heat source can be aconventional chemical heating apparatus, such as those producing anexothermic reaction when two or more separate materials are mixed, orare exposed to air. These can be packets of reactants in granular form,chemically activated gel heating sources, etc. The feeding apparatus canbe configured to cooperate with the heat source to heat the baby formulaor other food. In one embodiment, the kit can include an outer container(not shown) which is the outer wall of the double wall configurationmentioned. This can be a continuous wall, or can comprise vents (e.g. toexpose air to air-reactant heating pads). A mesh or other textile can beused as the material forming the outer containment in which the infantfeeding assembly is disposed. The outer container can be configured toreceive and protect the feeding assembly and can also encompass theheating source to maintain close contact between the heating source andthe hollow body 56.

In another embodiment, the heat source can be some other means ofproviding heat, for example provision of a metal outer sleeve, annularspace for water, and inner container for formula or food enabling use ofa cigarette lighter, a solar reflector or magnifier, or some otherhigher temperature heat source to heat the outer sleeve and still enablemore gentle warming of the contents of the inner sleeve. Such anarrangement would also facilitate rapid cooling of the outer sleeveafter removing the high temperature heat source so that it can be safelyhandled, enabling removal of the inner sleeve for feeding for example.

In another example embodiment of the invention, shown in FIG. 8, aplurality of single use packaged diapers (not shown), or diaper kits 40,40A can be provided packaged together, each stacked vertically in amaster container 60. The master container 60 can include a removableaccess panel (previously removed in FIG. 8) through which one 40 of theplurality of containers can be accessed. Providing for the removableaccess panel can be in one of a variety of ways known to those in theart, including a perforated removable panel or hinged panel. A bottom 62of the access panel can be disposed in the master container 60 in alocation vertically displaced from a bottom 64 of the master containerby a distance substantially equal to a height “h” of the container. Ithas been found that having the last container to be used positionedbelow the access panel helps keep the shape of the master container andimproves appearance over the dispensing life of the product.

In this manner, as a kit is removed from the master container, the kitimmediately above the removed kit will fall into place to be easilyremovable from the master container. Notches 66 can be provided adjacentthe removable panel to enable easy withdrawal of kits through the panel.The master container 60 can be used to package and ship a number of kits40, and advantageously also used to dispense the kits at a retail centeror other point of sale. While the master container shown in FIG. 7 isconfigured to store and dispense 6 diaper kits, master containersconfigured to store and dispense fewer or more kits can also beprovided, and include two or more access panels disposed and oriented ina variety of locations on the master container.

Illustrated in FIGS. 9A and 9B is a diaper kit 68 in accordance withanother example implementation of the invention. In this embodiment, adiaper 70 and various diaper accessories 72 are contained within anencasement 74. The accessories can include baby ointment, baby wipes,powder, etc. as discussed above. In this example the accessories includebaby ointment 72A and wipes 72B. Other accessories can be substituted oradditionally included. Shown at 76 are seams formed in the encasementdefining adjacent compartments that can each hold a different product.The seams can separate products to enable differing treatment of theproducts in relation to the encasement. For instance, diaper 70 can bedisposed in the encasement in a reduced volumetric configuration, asdiscussed above, and the encasement can be evacuated and vacuum-sealedabout the diaper. However, the baby ointment 72A can be vacuum sealed(if already packaged in an impermeable containment without excess air)but need not be vacuum sealed (indeed it may be difficult to do so ifnot already packaged) in its corresponding compartment. Likewise thewipes 72 b are not vacuum packed, but could be if previously enclosed inan impermeable containment without excess air.

While it may be desirable to vacuum-pack the diaper 70, and it ispossible to do so with some accessories, it may be the case that certainaccessories are not well suited to such an arrangement. For instance,with regard to the previously mentioned examples of ointment 72 a andwipes 72 not pre-packaged, baby wipes are often saturated or at leastmoisture-laden with a liquid cleaning compound similar in appearance tosoapy water, to aid in the cleaning process associated with changingdiapers. When subjected to a vacuum, the moisture may be withdrawn fromthe wipes, leading to poor performance of the wipes. In addition, ifundue moisture is removed during the vacuum process, the moisture mayinterfere with sealing the encasement once vacuum has been drawn,leading to premature breach of the encasement. The same applies to theointment, it would be likewise problematic to vacuum pack it, even moreso. Thus, for some products a vacuum seal may not be desirable ornecessary, and those products can be sealed in the encasement withoutbeing placed under vacuum.

To address these issues, the present invention in one embodimentadvantageously provides a diaper kit that can include differently andvariably treated compartments. In the example shown, the compartmentcontaining the diaper 70 can be treated with a vacuum to aid inmaintaining the volumetrically reduced configuration of the diaper. Thecompartment holding the ointment 72A may or may not be vacuum treated,as the situation dictates. The compartment holding the wipes 72B can besimply sealed to retain the moisture in the wipes without drawing anymoisture out with a vacuum process. Other compartments (not shown) canbe treated according to the product stored in each one.

In addition to the compartmentalized encasement shown in FIGS. 9A and9B, it is contemplated that in another example embodiment of theinvention, shown in FIG. 9C, one can provide a diaper kit 68′ in whichall of the components of the kit are contained in an encasement 74′ andsealed under vacuum. For example, the diaper wipes 69 and/or otheraccessories can be pre-packaged in one or more casings 74″ with liquidand wipe material therein. In this way, both a diaper and one or moreaccessories, together forming a single use kit, can be integrallypackaged in one encasement 71′, and can all be accessed once theencasement has been breached.

With reference to FIGS. 10A through 10E, in one embodiment of theinvention the encasement in which the volumetrically reduced diaper isdisposed can contain the diaper without any substantial pressuredifferential acting upon the encasement. One illustrative process inwhich this can be achieved is illustrated in FIGS. 10A through 10E. Inthis embodiment, a “loose” diaper 80 is placed within a chamber 84B witha pair of encasement shells 82 disposed adjacent ends of the diaper.Rams 86 and 88 can be activated to compress the diaper into avolumetrically reduced configuration, as illustrated in FIG. 10B. Onceoptimal reduced volume is achieved, the diaper/shell assembly can bemoved adjacent a channel 85 defined between the chambers 84A and 84B, asillustrated in FIG. 10C.

Channel 85 can provide access to the diaper/shell assembly to enableattachment of a clamping strap 90 to the shells 82. The strap can aid inmaintaining relative position of the shells 82 after the pressureapplied to reduce the volume of the diaper is released. Thus, as shownin FIG. 10E, the rams 86, 88 and chambers 84 can be removed from contactwith the diaper, and the encasement maintains the diaper/shell assemblyin the volumetrically reduced configuration. In this manner, it is notnecessary to apply a vacuum to the encasement to create and maintain thevolumetrically reduced size of the diaper. In another embodiment, theencasement can be made air tight by application of the clamping strap,and thus a combination of differential pressure and hoop strength of theencasement can contain the diaper after the encasement expands to anequilibrium state.

As shown in FIGS. 11A and 11B, in one aspect of the invention, arestraint 92 can be provided in which the diaper 12 can be disposed asecond, reduced size, relative to a first, nominal size. The restraint92 can confine the diaper so that the diaper is retained in its reducedsize by the restraint and so that the diaper is returned to its nominalsize upon opening of the restraint. The restraint can be a strap or aseries of independent or interconnected straps, or, as shown in FIG.11B, the restraint 94 can include a webbed material. The restraint canbe formed of a material having sufficient strength to retain the diaper12 in the reduced size, but can be removed by a consumer to release thediaper into the first, nominal size, for example by exploiting anengineered weakness, as is conventionally provided in “tear-away”packaging closures.

FIGS. 12–26 represent color photographs of a process of vacuum-packingof an individual diaper using a vacuum-sealing machine. In this respect,FIG. 12 illustrates a photograph of both an unpackaged diaper havinggraphical indicia printed thereon and a corresponding diaper that hasbeen vacuum-packed in accordance with the invention. FIGS. 13–15illustrate photographs showing the folding of an unpackaged diaper inpreparation for vacuum-packing of the diaper. FIGS. 16–18 illustratephotographs showing compression of the diaper using a clamping device inpreparation for vacuum-packing of the diaper. FIG. 18 also illustrates aphotograph in which a vacuum-packed diaper is shown. FIGS. 19–21illustrate photographs showing insertion of a compressed diaper into atransparent encasement. FIGS. 22–25 illustrate photographs showing thevacuum-sealing of the compressed diaper within the encasement using a“SUPER VAC” vacuum-sealing machine, and FIG. 26 illustrates a photographshowing the resulting vacuum-sealed diaper within the encasement.

It is to be understood that the above referenced arrangements areillustrative of the application for the principles of the presentinvention. It will be apparent to those of ordinary skill in the artthat numerous modifications can be made without departing from theprinciples and concepts of the invention as set forth in the claims.

1. A method of making a diaper kit that includes miniaturizing a singleunused disposable diaper by folding and vacuum-sealing, the diaper whenworn having both an exterior surface including a front exterior surfaceand a rear exterior surface, and side elastic banded edges extendingabout leg openings, the method comprising the steps of: (a)miniaturizing a single unused disposable diaper by, (i) transitioning adiaper from an initial configuration having an initial volume to anintermediate configuration having an intermediate volume, theintermediate volume being less than the initial volume by, (A) foldingthe diaper such that the width of the diaper is reduced and the sideelastic banded edges of the diaper are folded inward by, (I) folding thediaper about a first lengthwise foldline located between the sideelastic banded edges of the diaper, and (II) folding the diaper about asecond lengthwise foldline located between the side elastic banded edgesof the diaper, and (B) folding the diaper along at least one widthwisefoldline such that the length of the diaper is reduced generally by atleast 50%, a height of the diaper being increased thereby, (C) whereby acentral portion of the exterior surface of the diaper is visible and theremainder of the exterior surface of the diaper is hidden from viewwithin the folds of the diaper, and (D) after said folding of said steps(a)(i)(A) and (a)(i)(B), reducing the height of the folded diaper bycompressing the diaper with opposed surfaces of a press; and (ii) afterperformance of said transitioning of the diaper to the intermediateconfiguration, further transitioning the diaper to a final configurationhaving a final volume that is less than the intermediate volume byvacuum-sealing the diaper within an encasement, the encasement having aninterior volume that closely corresponds to the intermediate volume ofthe diaper, said vacuum-sealing including sealing the diaper within theencasement under a vacuum that is sufficient to result in furthercompression of the diaper to a very firm and dense state in which thecentral portion of the exterior surface of the diaper is hard; and (b)forming a diaper kit having a miniaturized diaper by packaging togetherboth, (i) said vacuum-sealed diaper, and (ii) a diaper accessory used inchanging a diaper; (c) wherein the combined packaging resulting fromsaid step (b) includes the diaper and the diaper accessory being locatedwithin separate interior spaces of the diaper kit, the separate interiorspaces being isolated from one another by an air impermeable materialsuch that different pressures may exist in the respective interiorspaces of the diaper kit.
 2. The method of claim 1, wherein the vacuumunder which the diaper is sealed within the encasement is between about5 mbar and 1 mbar.
 3. The method of claim 1, wherein the width of thediaper is reduced generally by at least 50% in said step (a)(i)(A). 4.The method of claim 1, wherein the length of the diaper is reducedgenerally by at least 33% in said step (a)(i)(B).
 5. The method of claim1, wherein the length of the diaper is reduced generally by at least 25%in said step (a)(i)(B).
 6. The method of claim 1, wherein the diapervacuum-sealed within the encasement includes a generally rectangularconfiguration having three dimensions comprising a width, length, andheight, and wherein the sum of two of said three dimensions is less than10 cm with no single dimension of said three dimensions exceeding 10 cm.7. The method of claim 1, wherein the diaper vacuum-sealed within theencasement includes a generally rectangular configuration having threedimensions comprising a width, length, and height, and wherein none ofthe three dimensions exceeds about four inches.
 8. The method of claim1, wherein the diaper vacuum-sealed within the encasement includes agenerally rectangular configuration having three dimensions comprising afinal width, final length, and final height, and wherein the finalheight is approximately equal to an initial height of the diaper in theinitial configuration.
 9. The method of claim 1, wherein the diapervacuum-sealed within the encasement includes a generally rectangularconfiguration having three dimensions comprising a final width, finallength, and final height, and wherein the final length is between twoand four inches and wherein the final height exceeds neither the finallength nor the final width.
 10. The method of claim 1, wherein theencasement comprises at least a portion thereof that is transparent suchthat the diaper is viewable through the encasement.
 11. The method ofclaim 1, wherein the vacuum-sealed diaper includes printed indiciathereon, and further comprising the step of arranging the vacuum-sealeddiaper within the encasement such that the printed indicia is visiblethrough a transparent portion of the encasement.
 12. The method of claim1, wherein the diaper is the only diaper disposed within the encasement.13. The method of claim 1, wherein the diaper is the only diaperdisposed within the diaper kit.
 14. The method of claim 1, wherein thediaper accessory comprises moist wipes that are prepackaged within amoisture impermeable encasement.
 15. The method of claim 1, wherein thediaper accessory comprises one of the group of cologne, perfume, and anodor-reducing spray.
 16. The method of claim 1, wherein the diaperaccessory comprises a dirty diaper disposal bag.
 17. The method of claim1, wherein the encasement in which the diaper is vacuum-sealed comprisesa flexible, air impermeable material.